https://ntrs.nasa.gov/search.jsp?R=20150021395 2019-08-31T05:45:00+00:00Z

In-space Manufacturing: Pioneering a Sustainable Path to Mars Rocket City Science Cafe September 8, 2015

Niki Werkheiser NASA In-space Manufacturing Project Manager Niki.Werkheiser@nasa.gov 256-544-8406 • ISM is responsible for developing the on-demand manufacturing capabilities that will be required for affordable, sustainable operations during Exploration Missions (in- transit and on-surface) to destinations such as Mars. This includes advancing the needed technologies, as well as establishing the skills & processes (such as certification and characterization) that will enable the technologies to go from novel to institutionalized. • These technologies are evolving rapidly due to terrestrial markets. ISM is leveraging this commercial development to develop these capabilities within a realistic timeframe and budget. • ISM utilizes the International Space Station (ISS) as a test-bed to adapt these technologies for microgravity operations and evolve the current operations mindset from earth-reliant to earth-independent.

TECHNOLOGIES SKILLS & PROCESSES Design Characterize Certify Optimize

On-demand Manufacturing Capability for Exploration Missions More than just 3D Printing…. In-space Manufacturing Technology Development Areas

MULTI EXTERNAL ADDITIVE RECYCLER PRINTED PRINTABLE MATERIAL STRUCTURES CONSTRUCTION ELECTRONICS SATELLITES 3D PRINTING & REPAIRS

Contour Crafting Simulation Plan Recycling/Reclaiming Leverage ground- The combination of Additively Astronauts will perform based developments to 3D Print coupled with manufacturing metallic repairs on tools, for Lunar Settlement 3D Printed Parts Infrastructure Build-Up enable in-space Printable Electronics parts in space is a components, and and/or packing B. Khoshnevis, USC materials into manufacturing of enables on-orbit desirable capability for structures in space feedstock materials. functional electronic capability to produce large structures, high using structured light This capability is components, sensors, “on demand” strength requirement scanning to create crucial to and circuits. satellites. components (greater digital model of damage sustainability in- Image: Courtesy of Dr. than nonmetallics or and AM technologies space. Jessica Koehne composites can offer), such as 3D Print and (NASA/ARC) and repairs. NASA is metallic manufacturing Illustration of a lunar evaluating various technologies (e.g. habitat, constructed technologies for such E-beam welding, using the Moon's soil applications. Image: ultrasonic welding, and a 3D printer. Manufacturing EBF3) to perform the Credit: Foster+Partners Establishment website repair. Image: NASA

ISM Technologies Under Development for Sustainable Exploration Missions In-space Manufacturing (ISM) Path to Exploration

EARTH RELIANT PROVING GROUND EARTH INDEPENDENT

ISS Platform • In-space Manufacturing Rack Demonstrating: o 3D Print Tech Demo (plastic) • Additive Manufacturing Facility • Recycling • On-demand Utilization Planetary Surfaces Platform Catalogue ISS • Additive Construction, Repair & • Printable Electronics Recycle/Reclamation Technologies (both In- • In-space Metals situ and Ex-situ ) • Syn Bio & ISRU • Provisioning of Regolith Simulant Materials • External In-space Mfctr. & Repair for Feedstock Utilization Demo Commercial • Execution and Handling of Materials for Cargo and Crew Fabrication and/or Repair Purposes Space Launch System • Synthetic Biology Collaboration Asteroids

Earth-Based Platform • Certification & Inspection Process • Material Characterization Database (in-situ & ex-situ) • Additive Manufacturing Systems Automation Development • Ground-based Technology Maturation & Demonstrations (i.e. ACME Project) • Develop, Test, and Utilize Simulants & Binders for use as AM Feedstock

* Green text indicates ISM/ISRU collaboration In-space Manufacturing Phased Technology Development Roadmap

Earth-based Demos: Ground & ISS Exploration Mars Asteroids Lunar

Lagrange Plastic Printing Recycler Metal Demo Printing Point SmallSats Self-repair/ Add Mfctr. Printable replicate Facility Electronics External In- 3D Print Tech Demo space Mfctr Pre-2012 2014 2015 2016 2017 2018 2020-25 2025 2030 - 40 • In-space:3D • 3D Print Demo Ground & Parabolic ISS: Lunar, Lagrange Planetary Mars Multi-Material Print: First • Future Engineer FabLabs centric: Challenge Utilization/Facility Surfaces Fab Lab Plastic Printer • Initial • Multiple FDM Zero- • Utilization Focus Points Fab • Provision & Utilize on ISS Tech Robotic/Remote G parabolic flights Catalogue • In-space Recycler • Transport in situ resources Demo Missions for feedstock • Trade/System • ISM Cert Demo vehicle and • NIAC Contour • Provision • FabLab: Provides Studies for Metals Process • Integrated Facility sites would Crafting • Add. Mfctr. feedstock on-demand • Ground-based Systems for need Fab • NIAC Printable Facility (AMF) • Evolve to utilizing manufacturing of Printable stronger types of capability Spacecraft • In-space in situ materials structures, Electronics/Spacec extrusion materials • Additive • Small Sat in a Recycler SBIR (natural electronics, & parts raft for multiple uses Construction Day • In-space resources, utilizing in-situ and • Verification & Material including metals & & Repair of • AF/NASA Space- synthetic biology) ex-situ (renewable) Certification Database various plastics large based Additive • Product: Ability to resources. Includes Processes under • External In- • Printable structures ability to inspect, NRC Study produce, repair, development space 3D Electronics Tech recycle/reclaim, and • ISRU Phase II and recycle parts • Materials Database Printing Demo post-process as SBIRs • Autonomous & structures on • Cubesat Design & • Synthetic Biology needed • Ionic Liquids Processes demand; i.e.. Development Demo autonomously to • Printable • ACME Simulant “living off the • Metal Demo ultimately provide Electronics Dev. & Test for land” Options self-sustainment at Feedstock; • Autonomous final Ground Demo • ACME Ground remote destinations. milling to Demos specification ISS Serves as a Key Exploration Test-bed for the Required Technology Maturation & Demonstrations * Green text indicates ISM/ISRU collaboration • The 3D Print Tech Demo launched on SpaceX-4 (9/21/14) and was installed in the Microgravity Science Glovebox on ISS. The printer was designed and built by Made in Space, Inc. under NASA Small Business Innovation Research contract. • To date, 21 parts have been printed in space (13 unique designs); the printer functioned nominally. • First part “emailed” to Space: 3D Print of a ratchet tool demonstrated on-demand capability by uplinking a part file that was not pre-loaded to the 3D Printer. • The first flight samples were ‘unboxed’ at NASA MSFC in April 2015. Test & Analyses is underway with results to be openly published Fall 2015

Clamps

Images courtesy of NASA 3D Printer International Space Station (ISS) Technology Demonstration Initial Samples Mechanical Property Test Articles Functional Tools Crowfoot Wrench

Tensile Compression

Cubesat Container Clip

Flex Torque

Printer Performance Capability

Calibration Hole Resolution Feature Resolution Overhang Layer Quality In-Space Manufacturing Tasks

 Material Characterization Database Development • Objective: Characterize microgravity effects on printed parts and resulting mechanical properties. Develop design-level database for microgravity applications. • MSFC team has performed initial characterization on ABS and ULTEM using various printer and feedstock vendors. • MSFC will generate design property database from ground samples produced using the flight spare 3D printer. Housekeeping • Phase II operations for additional on-orbit prints of Vacuum Crevice Tool engineering test articles, as well as utilization parts, are being planned with ISS for later this year. ISM • All datasets will be available through the MSFC Characterization Materials and Processes Technical Information of Materials and Process System (MAPTIS) Variability  On-demand ISM Utilization Catalogue (above) Development • Objective: Develop a catalogue of approved parts for in-space manufacturing and utilization. • Joint effort between MSFC AM materials and process EVA Suit Fan Shipping Container: Design experts and space system designers and JSC ISS Clearances had to be Crew Tools Office relaxed for part to be printed on one FDM printer • Parts being assessed include crew tools, payload (red) vs. another in order components, medical tools, exercise equipment for the parts to be replacement parts, cubesat components, etc. assembled. • First parts are in design and ground test process. In Space Manufacturing Tasks

 AMF - Additive Manufacturing Facility (SBIR Phase II- Enhancement) with Made In Space, Inc. • Commercial printer for use on ISS . Incorporates lessons learned from 3D Printer ISS Tech Demo . Expanded materials capabilities: ABS, ULTEM, PEEK . Increased build volume • Anticipated launch late CY2015 Additive Manufacturing  In-space Recycler ISS Technology Demonstration Facility (AMF) Development (SBIR 2014) • Objective: Recycle 3D printed parts into feedstock to help close logistics loop. • Phase I recycler developments completed by Made In Space, Inc. (MIS) and Tethers Unlimited, Inc.. • Phase II SBIR (2014) awarded to TUI) • Final deliverable will result in flight hardware for the In- space Recycler for proposed ISS Technology Demonstration in FY2017.  Launch Packaging Recycling Phase I SBIR (2015) • Objective: Recycle packaging materials (foam, bubble wrap, plastic bags) into useable 3D Printing feedstock to help close logistics loop. • Awarded TUI, Cornerstone, and Techshot Phase I SBIRs Tethers Unlimited SBIR to Develop ISS Recycler Tech Demo In-Space Manufacturing Tasks  In-space Printable Electronics Technology Development • Development of inks, multi-materials deposition equipment, and processes • Collaborating with Xerox Palo Alto Research Center (PARC) on Printable Electronics technologies developed at MSFC and Xerox PARC. • NASA Ames Research Center developing plasma jet printable electronics capability • Jet Propulsion Lab (JPL) has Advanced Concepts project to develop “printable spacecraft”

• “Printing” ultracapacitors, RFID tags & antennae, & Printable boards in one process Electronic Technologies • Printable Electronics Roadmap developed targeting ISS technology demonstrations including RF sensors/antennae, in-space printed solar panel, and printable cubesats  In-space Multi-Material Manufacturing Technology Development • In-space Adaptive Manufacturing (ISAM) project with Dynetics utilizing the Hyperbaric Pressure Laser Chemical Vapor Deposition (HP-LCVD)

• HP-LCVD technology holds promise for a novel solution to Spring Created manufacturing with multiple materials (including metallics by Adaptive & composites) in microgravity. Manufacturing • Phase I deliverable in September 2015 is spring similar to design utilized on ISS in furnaces In Space Manufacturing Collaborations

 ACME - Additive Construction by Mobile Emplacement (NASA STMD GCD & Army Corps of Engineers) • Joint initiative with the U. S. Army Engineer Research and Development Center – Construction Engineering Research Laboratory (ERDC-CERL) Automated Construction of Expeditionary Structures (ACES) Project • Objective: Develop a capability to print custom-designed expeditionary structures on-demand, in the field, using locally available materials and minimum number of personnel. • Goal: Produce half- scale and full-scale structures with integrated additive construction system at a lab or planetary analog site (September 2017) Additive construction Concept on extraterrestrial surface.  NASA/DARPA External In-space Manufacturing & Repair BAA (To Courtesy: B. Khoshnevis, CCC be released in FY16) • Objective: External Additive Manufacturing shows great promise for Exploration missions. A joint NASA/ Defense Advanced Research Projects Agency (DARPA) Broad Agency Announcement (BAA) is proposed to explore the technologies available today that could be utilized for a future in-space demonstration. • Targeted Areas of Interest for an External In-space Manufacturing & Repair Technology Flight Demo include: Additive Manufacturing Technologies, Printable Electronics, Autonomous & Remote Ops, Inspection - Manufacturing context, situational awareness and metrology, Ionic Liquids External In-space Manufacturing & Extraction & Utilization Repair Technologies In-space Manufacturing STEM & Outreach: Leveraging External Platforms for Technology and Skillset Development

National Future Engineers STEM Program: National challenge conducted jointly by NASA and American Society of Mechanical Engineers (ASME) o Competition was held in two divisions, Junior (K-12) and Teen (13-18)

o First Challenge was to design a tool that astronauts Future Engineers could use on ISS. Teen winner’s part will be printed on Winning Part – Multi-purpose ISS later this year. Maintenance Tool (MPMT) o The Space Container Challenge was announced on 5/12/15 and closes 8/2/15. www.futureengineers.org o Discussions underway for a joint NASA/IndyCar Challenge

NASA GrabCAD Handrail Clamp Assembly Challenge o GrabCAD has a community of nearly 2 million designers o Challenge was to design a 3D Printed version of the ISS Handrail Clamp Assembly GrabCAD (left) Handrail Clamp Assembly commonly used on ISS & traditional (right) o Nearly 500 entries in three weeks o Five winners were selected

12 In-space Manufacturing Initiative Summary

In order to provide meaningful impacts to Exploration Technology needs, the ISM Initiative Must Influence Exploration Systems Design Now.

• In-space Manufacturing offers: • Dramatic paradigm shift in the development and creation of space architectures • Efficiency gain and risk reduction for low Earth orbit and deep space exploration • “Pioneering” approach to maintenance, repair, and logistics will lead to sustainable, affordable supply chain model. • In order to develop application-based capabilities in time to support NASA budget and schedule, ISM must be able to leverage the significant commercial developments. • Requires innovative, agile collaborative mechanisms (contracts, challenges, SBIR’s, etc.) • NASA-unique Investments to focus primarily on adapting the technologies & processes to the microgravity environment. • We must do the foundational work – it is the critical path for taking these technologies from lab curiosities to institutionalized capabilities. • Characterize, Certify, Institutionalize, Design for AM • Ultimately, ISM will utilize an ISS US Lab rack to develop an integrated “Fab Lab” with the capability to manufacture multi-material parts with embedded electronics, inspect the parts for quality, and recycle multiple materials into useable feedstock that will serve Exploration Missions. 13 BACKUP

14 ISM WBS

1.0 In-Space NASA Technical Manufacturing Authority Chief Engineer Project Management Chief Safety Officer Resource Analyst

1.1 In-space 1.2 Materials 1.3 Parts 1.4 In-Space 1.5 STEM Manufacturing Characterization Utilization External Outreach Technologies Catalogue Manufacturing & Repair

3D Printing in Material Catalogue Future Zero-G Tech External In- Properties Needed Content Engineers Demo for Design using space Additive Definition Challenges FDM Manufacturing Additive and Repair Manufacturing Develop Technology Develop Material GRAB CAD Facility (AMF) Catalogue Development Properties Database Format Challenge Database and Structure In-space Recycling DARPA/NASA Capability Develop Design Develop Process BAA & Analyses for Candidate Printable Tools & Models Part Inclusion Electronics - Sample Part Dev Quantification of - Verification & In-Space Metals Variables Validation Process Dev Printing Affecting Baseline Database Autonomous and - Microgravity Remote - Printer Capability Operation - Feedstock Technologies - Recycler Process 15 ISM Level – 1-4 Requirements Decomposition

Level 1 Level 2 Level 3 Level 4 HQ - Level 1 Objective AES, STMD and ISS Program - Level 2 In-Space Manufacturing (Former 3D Print) Project Level 4 Requirements - Requirements - Level 3 Requirements Made In Space Contract and In-house Task New Expanded Requirements for In-Space Manufacturing in Addition to Original 3D Print Above Utilize ISS as a Test Bed to further TRL maturation on The In-Space Manufacturing Project shall develop enabling and critically enhancing technologies needed and institutionalize a Verification and Certification for long duration human exploration beyond earth orbit Process for candidate parts to be included in the parts cataloge that ensures that the part designs meet all functional and ISS interface / safety requirements. In-Space Manufacturing shall develop a The In-Space Manufacturing Project shall develop a parts cataloge of pre approved items that process for identifying candidate parts for addition to can be printed in-space to support ISS and parts cataloge database Exploration needs. The In-Space Manufacturing Project shall develop an electronic database cataloge of pre approved items parts that can be called up and printed on an as needed basis

OCT Materials, Structures, Mechanical Systems, & The In-Space Manufacturing Project shall develop a The In-Space Manufacturing Project shall utilize Manufacturing Road Map, Technology Area 12 Material Characterization Database that quantifies MAPTIS to publish results for the material - Table 18 Page TA12-22,"d.in-space assemby, the material properties of print material in the as database fabrication and repair introduction of new materials printed state such as needed by a design engineer to and methods to fabricate structures in-sapce" facilitate the design of parts in the parts cataloge -Sec 5.2.1 para 6 p TAI2-31, "Enable cost-effective manufacturing for reliable high performance structures The In-Space Manufacturing Project shall develop The In-Space Manufacturing Project shall ensure and mechanisms made in low-unit production, NASA customer goals and requirements for an In- that the lessons learned from the 3D Print including in space manufacturing" Space Manufacturing Facilities both for commercial, Technology Demonstration are integrated into -Sect 5.3 12.4.2 Intellegent Integrated Manufacturing ISS and exploration applications. the AMF printer and will be applicable to NASA and Cyber Physical Systems (Manufacturing) p TA12- ISM objectives. 33, "This technology would enable physical In-Space Manufacturing shall develop The In-Space Manufacturing Project shall develop a The In-Space Manufacturing Project shall components to be manufactured in space, on long- production In Space Manufacturing design capability for Additive Manufacturing that develop and implement a procurement model for duration human missions if necessary. capability to support ISS & Future takes advantage of the microgravity and NASA to procure print services from the MIS Exploration Needs. exoplanetary environments. AMF commercial 3D Printer on ISS. In-Space Manufacturing Project shall develop printable electronics ground demo to enable additive manufacturing of electronic circuits for in space applications. NASA Human Research Program (HRP) Decadal The In-Space Manufacturing Project shall develop an Survey AP10 ISS in space recycler tech demo development to - Design and Devolop advanced materials tha tmeet enable use of available materials and minimize new property requirements to enable human launch of renewable resources. exploration at reduced cost using both current and novel materials synthesis and processing techniques and computational methods. The In-Space Manufacturing Project shall develop a quality assessment approach to assure that the parts printed are manufactured to the design requirements intended. The In-Space Manufacturing Project shall develop Automation & Sensor Development for Remote technology to enable automated remote in space operation of Additive Manufacturing additive manufacturing for ISS and explorations Technologies applications. The In-Space Manufacturing Project shall develop External In-space Manufacturing BAA technology to enable large scale structure manufacturing in the exposed vacuum environment of space. The In-Space Manufacturing Project shall develop technology to enable additive repair of tools, components and structures in space to cut dependence on earth to orbit replacement of damaged parts.

In-Space Manufacturing shall develop a The In-Space Manufacturing Project shall develop a STEM outreach program to gather interest Future Engineers Program 3D printing in space from the public challenge to design a tool that could be used in space including students in grades K-12. 16 3D Printing ISS Tech Demo Sample Testing Techniques

Visual and photographic Inspection • Identification and documentation of anomalies, damage (e.g., print tray removal damage) • Identification and documentation of any visual differences between flight and ground samples (initial identification of microgravity effects) • Attention will be given to any signs of delamination between layers, curling of the sample, surface quality, damage, voids or pores, and any other visually noticeable

defect. Visual Inspection of Flight and Ground Parts Mass Measurement / Density Calculation • Mass measurement using a calibrated laboratory scale accurate to 0.1mg repeated five times for a mean mass • Density calculation requires the volume determined by structured light scanning o Provides information on void space or expansion of the material created during the printing process o Flight samples will be compared with their respective ground samples to assess any differences Laboratory Scales utilized for Mass & Density Calculations 3D Printing ISS Tech Demo Sample Testing Techniques

Structured Light Scanning • ATOS Compact Scan Structured Light Scanner • Blue light grid projected on the surface • Stereo-images captured • Image processing provides o A CAD model of the printed part o A comparison of the printed part and the original CAD file from which the part was printed

o A statistically valid determination of the volume of the ATOS Compact Scan Structured sample Light Scanner

Computed Tomography (CT) Scanning/X-Ray • Phoenix Nanome|x 160 • X-ray scans • Provides 2D and 3D models of the internal structures that could affect mechanical properties o Internal voids o De-lamination of the ABS layers • Resolution as low as 8-10 microns is possible

Phoenix Nanomelx 160 CT Scan 3D Printing ISS Tech Demo Sample Testing Techniques

Mechanical (Destructive) Testing • ASTM Standards Applied on Mechanical Samples only • D638 for tensile testing o Tensile strength, tensile modulus, and fracture elongation • D790 for flexure testing o Flexural stress and flexural modulus • D695 for compression testing

o Compressive stress and compressive modulus Mechanical Samples for Destructive Testing Optical and Scanning Electron Microscopy

• Detail the surface microstructures of the layers Leica M205-A • Detail the surface of the flight prints damaged by over- Optical Microscope adhesion to the build tray; it is hoped this will identify the root cause of seemingly increased adhesion of part to tray • Inter-laminar regions will be investigated; flight and ground samples will be compared • Defects or anomalies noted by the initial inspection will be

examined, as well as the fracture surfaces from the Hitachi S-3700N mechanical tests Scanning Electron Microscope